Manufacturing method of friction plate for clutch

ABSTRACT

This invention relates to a manufacturing method and a manufacturing apparatus of friction plate for clutch. 
     The present invention intends to provide the manufacturing method and the manufacturing apparatus of friction plate for clutch which can adhere the plural friction material segments to the core plate in shorter time period than that in the conventional art. 
     The manufacturing method comprises a step for containing plural friction material segments  2  on a one surface  70   a  of a holding body  4  circumferentially; and a step for making the one surface of said holding body  4  and an adhering surface of a core plate  8  coated with an adhesive agent come near to each other, and for adhering the friction material segments  2  held by said holding body  4  to the adhering surface of said core plate  8  by urging.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a manufacturing method and a manufacturingapparatus of friction plate for clutch.

2. Related Art

A friction plate for clutch is used, in a clutch of a vehicle etc., tobrake a rotating member such as rotor. It is comprised of a ring-shapedcore plate and a plurality of friction material segments adhered to asurface of the core plate circumferentially. Japanese Patent PublicationNo. 4-68491 and Japanese Patent Laid-open No. 10-318309 have disclosedexamples for manufacturing method and the manufacturing apparatus offriction plate for clutch. The manufacturing methods of the frictionplate for clutch disclosed in these prior arts comprise a punching stepfor punching the friction material tape by a punching unit to form onepiece of friction material segment, and a adhering step for adhering thepunched friction material segment to an adhering surface of a core platecoated by an adhesive agent.

In detail, a band-shaped friction material is supplied above the coreplate radially inwardly or tangentially to be punched into the frictionmaterial segment of a predetermined shape by the punching unit includinga die and a punch. Then, the punched friction material segment isadhered to the adhering surface of the core plate by the punch justbelow the punching position. After adhering of the friction materialsegment to the core plate, the band-shaped friction material is suppliedby the predetermined length and the core plate is rotated by thepredetermined angle synchronous therewith, to perform forming andadhering of the next friction material segment. With repeating thepunching step and the adhering step alternately by the times equivalentto the number of the friction material segments, all of the frictionmaterial segments have been adhered to the core plate circumferentially.

The manufacturing apparatus of friction plate for clutch is comprised ofa supporting table supporting the core plate and intermittently rotatingin every adhering of the friction material segment to the core plate, asupplying member for intermittently supplying the band-shape frictionmaterial over the supporting table by a predetermined lengthcorresponding to length of the friction material segment, and a pressingmember (punching unit) for punching the band-shaped friction materialand for adhering the punched friction material segment to the coreplate.

However, the above-mentioned manufacturing method and the manufacturingapparatus of Japanese Patent Publication No. 4-68491 and Japanese PatentLaid-open No. 10-318309, punching the band-shaped friction material andadhering the punched friction material segment to the core plate by thepressing member alternately by times equivalent to the number of thefriction material segments, has been suffering from the followingdisadvantages.

A first disadvantage results from a characteristic change of theadhesive agent coated onto the core plate. Due to repeating punchingstep and the adhering step performed for each friction material segment,long time period is required from adhering of the first frictionmaterial segment to adhering of the last friction material segment.Therefore, characteristic of the adhesive agent having been coated onthe core plate prior to punching of the band-shaped friction materialchanges between a start and an end of the friction material segmentadhering to the core plate. Thus, adhering condition delicately differfor each of the friction material segments.

As a result, when all of the friction material segments are adhered tothe core plate, particular friction material segment(s) may shiftradially and/or circumferentially from a desired position on theadhering surface. Thus, positioning accuracy of the friction materialsegment may be deteriorated, which changes a relative position betweenthe particular friction material segment and the friction materialsegment adjacent thereto. Thus, orientation and width of a radial grooveformed between opposing sides of the adjacent friction material segmentsmay change.

A second disadvantage results from wear of the punching unit. The dieand the punch included in the punching unit forms one friction materialsegment by one operation thereof. So, for forming the plurality offriction material segments by the band-shaped friction material, thesame die and punch are used by the plural times equivalent to the numberof friction material segments. In addition, the same blade portion ofthe die and that of the punch are repeatedly abutted to the band-shapedfriction material in every punching to be worn. Thus, the punching unitdecreases punching ability thereof in short time period and requires tobe changed.

As mentioned above, in the conventional manufacturing method and themanufacturing apparatus of friction plate for clutch, there has beenroom for improvement in the insufficient positioning accuracy of thefriction material segment on the core plate. It results from unevenadhering condition of the plural friction material segments due tolonger adhering time period. Also, there has been room for improvementin earlier wear of the blade portion of the punching unit and earlierexchange of the punching unit. It results from the same blade portion ofthe punching unit abutting to the band-shaped friction materialrepeatedly by times equivalent to the number of the friction materialsegments to be worn.

SUMMARY OF THE INVENTION

The present invention has been achieved in view of the abovecircumstances and intends to provide the manufacturing method and themanufacturing apparatus of friction plate for clutch which can overcomethe above disadvantages of the conventional art. That is, themanufacturing method and the manufacturing apparatus of the presentinvention can adhere the plural friction material segments to the coreplate in shorter time period than that in the conventional art. Thus,shifting of the friction material segment(s) in the circumferentialand/or radial direction of the core plate due to uneven adheringcondition can be prevented.

Also, the present invention intends to, in connection with theabove-mentioned adhering manner of the friction material segments to thecore plate, provide the manufacturing method and the manufacturingapparatus which can extend the durability life of the punching unit.

Inventors of the present invention pay attention to the fact thatabove-mentioned disadvantage results from punching the band-shapedfriction material and adhering the friction material segments beingrepeated for each friction material segment, that is, the adhering stepbeing carried out by the times equivalent to the number of the frictionmaterial segments. They hit on such disadvantages may be overcome bydecreasing the number of time for adhering the friction material segmentto the core plate.

A method for manufacturing a friction plate for clutch, comprising stepsof a step for containing plural friction material segments on a onesurface of a holding body circumferentially; and a step for making theone surface of said holding body and an adhering surface of a core platecoated with an adhesive agent come near to each other, and for adheringthe friction material segments held by said holding body to the adheringsurface of said core plate by urge.

The manufacturing method of the present invention can adhere in theadhering step the plural friction material segment held on one surfacethereof in the containing step to the adhering surface of the core platesimultaneously or in very short time period. Thus, the time periodrequired for adhering the plural friction material segments to the coreplate has been greatly reduced compared with that in the conventionalmanufacturing method, so that all of the friction material segments areadhered to the core plate in the same adhering condition. As a result,the radial or circumferential shifting of the particular frictionmaterial segment can be prevented.

Also, the containing step, not including any adhering step betweencontaining of the preceding friction material segment and the succeedingfriction material segment, can contain the plural friction materialsegments into the holding body continuously. As a result, a punchingunit of type punching the band-shaped friction material to form thefriction material segment continuously at different punching blade partscan be adopted. Such punching unit can decrease the using frequency ofthe punching blade greatly to extend the durability life thereof.

Further, fiber fabrics formed around the friction material segment inpunching the friction material tape by the first urging member extendopposite to pressing-in direction of the friction material segment intothe holding body. However, the friction material segment is pushed outfrom the holding body opposite to the push-in direction in adhering tothe core plate. So, the fiber fabrics nipped by the core plate and thefriction material segment can not be observed, which improve appearanceof the friction plate for clutch.

On the other hand, an apparatus for manufacturing a friction plate forclutch, comprising a holding body having a one surface for containingplural friction material segments circumferentially; a first urgingmember for urging the friction material segments to contain them in saidholding body; a supporting member for supporting a core plate having anadhering surface coated by an adhesive agent; and a second urging memberfor urging the friction material segments held in said holding body tosaid core plate, at position where the one surface and the adheringsurface come near to each other.

The manufacturing apparatus of the present invention can adhere theplural friction material segments held on one surface of the holdingbody simultaneously or in very short time period by urging with thesecond urging member.

In addition, the second urging member does not adhere any frictionmaterial segment between containing of the preceding friction materialsegment and the succeeding friction material segment by the first urgingmember. For this reason, the holding body and the first urging membercan contain the friction material segments on one surface continuouslyby cooperation therebetweeen. As a result, a segment preparing member(punching unit) of type punching band-shaped the friction material toform the friction material segment continuously at different punchingblade parts can be adopted. Such segment preparing member can decreasethe using frequency of the punching blade greatly to extend thedurability life thereof.

(Embodying Mode of the Manufacturing Method of Friction Plate forClutch)

As mentioned above, the manufacturing method is comprised of thecontaining step and the adhering step.

The friction material segments are prepared in advance in a segmentpreparing step for punching or cutting a band-shaped friction materialto form the friction material segment. The segment preparing step canpunch the plural friction material segment continuously orintermittently. Also, the segment preparing step can be carried out forthe band-shaped friction material obtained by compressing a band-shapedfriction blank material with heating it. The band-shaped friction blankmaterial can have plural cavities spaced longitudinally thereof or agroove extending longitudinally thereof. The segment preparing step iscarried out prior to the containing step to be explained next, but theycan be carried out continuously in one step or can be independentlycarried out in different or separate steps. The segment preparing stepand the adhering step to be explained later can be carried out indifferent step concurrently.

Next, the containing step will be explained. The containing step cancontain the friction material segment(s) into the holding body in avertical direction toward one surface, ie, in a vertical directionrelative to a surface of the friction material segment. This isconvenient when one surface is formed on end surface of thecircular-plate-shaped holding body. The containing step can contain thefriction material segment(s) into the holding body along (parallel to)one surface radially inwardly, that is, in parallel direction relativeto the surface of the friction material segment. This is convenient whenone surface is formed by a step or a recess formed along an outerperipheral edge the circular-plate-shaped holding body.

The friction material segments can be contained by urging. For theurging, mechanical means such as an urging member etc. or hydraulicmeans such as air cylinder or an oil cylinder can be used. For themechanical means, rod-shaped urging member advancing and retractingvertical to one surface can be adopted, which can ensure containing ofthe friction material segment into the holding body. For the hydraulicmeans, the holding member can have, at area where the segment containingportion is formed, an absorbing portion for absorbing the frictionmaterial segment under the reduced pressure. Absorbing the frictionmaterial segment can make the above rod-shape urging member unnecessary.

The containing step can contain, after having contained at least onefriction material segments, the friction material segment(s)sequentially in the circumferential direction of the holding body. Inother words, the two or more friction material segments can be containedinto the holding body one by one. In this case, the containing step caninclude a positioning sub step for positioning each of the containedfriction material segments at each of supplying portions by rotating theholding body, after each of the friction material segments is containedinto each of the supplying portions. Rotating the holding body in thecontaining step of the friction material segments allows to supply thefriction material segments at one or few supplying position(s). Also, itpositions the contained friction material segment(s) at the supplyingposition spaced circumferentially on one surface of the holding body.

In addition, the containing step can contain at least two frictionmaterial segments simultaneously. In this case, two or more frictionmaterial segments are supplied into the non-rotatable holding body attwo or more positions on one surface spaced circumferentially. Suchcontaining manner can shorten time period for containing the frictionmaterial segments into the holding body.

A plurality of segment supplying portions (holding portions) arepreferably formed on one surface of the holding body circumferentially.The segment holding portions can be comprised plural holding portionsspaced circumferentially, or can be comprised of one ring-shaped holdingportion. Also, the segment holding portion can be comprised of pluralspaced concaved portions or one concaved groove formed on the endsurface of the circular-plate-shaped holding body (here, bottom surfacesof the concaved portions or a bottom surface of the concaved grooveforms the one surface). Further, it can be comprised of pluralcircumferentially spaced recesses or steps or one ring-shaped recess orstep formed on an outer peripheral edge (corner) of thecircular-plate-shaped holding body (here, a bottom surface(s) of therecess(es) or step(s) forms (form) the one surface). Plural frictionmaterial segments are preferably held on the one surface so thatopposing sides of the adjacent friction material segments becomeparallel in the radial direction of the holding body.

Next, the adhering step will be explained. There is no restriction ofpositional relation between a containing position to contain thefriction material segments into the holding body and an adheringposition to adhere the friction material segments to the core plate.Accordingly, they can be positioned on the same axis, or on thedifferent (parallel, for example) axes. However, in view of members orelement required for containing and adhering the friction materialsegment, they are preferably disposed on different axes. In this case,the holding body and/or the core plate need to be moved so that the onesurface and the adhering surface come near to each other. For thispurpose, only the holding body or only the core plate can be moved, orboth of the holding body and the core plate can be moved. When theholding body moves to and from the fixed core plate, it can revolveabout a revolving axis, or can move in a direction parallel or verticalto the one surface thereof.

The adhering direction of the friction material segment to the coreplate and the containing direction of the friction material segment intothe holding body can be selected in opposite directions on the same axisor parallel axes, or in crossing (vertical, for example) directions. Thefriction material segments held in the holding body can be adhered tothe core plate by an urging member held in the holding body shiftablyrelative thereto. The urging member can be driven by a driving portionsuch as an air cylinder or an oil cylinder. Such urging member canadhere (push out) the friction material segments to the core plate moresecurely. Also, the friction material segments held in the holding bodycan be adhered to the core plate by the urge using an absorbing.Further, the adhering step can adhere all of the contained frictionmaterial segments simultaneously, which can greatly shorten the timeperiod necessary for adhering the plural friction material segments tothe core plate.

The embodying modes described in each of the containing step, theadhering step and the segment preparing step capable of selectivelycombining should be noted.

(Embodying Mode of the Manufacturing Apparatus of Friction Plate forClutch)

As mentioned above, the manufacturing apparatus is comprised of theholding body, the first urging member, the supporting member, and thesecond urging member.

The friction material segment can be prepared by punching or cutting aband-shaped friction material. The band-shaped friction material formedby compressing a band-shaped friction blank material to a predeterminedthickness can be used. The band-shaped friction material can have pluralcavities spaced longitudinally, or one groove extending longitudinally.

The segment preparing member can be provided independent from the firsturging member to be explained next, or a part thereof can be formed bythe first urging member. In the former case, the segment preparingmember can be comprised of a rotatable cutting roller having pluralcutting blades on an outer peripheral surface thereof. It can formplural friction material segments simultaneously. The latter case willbe explained in the column of the first urging member.

The holding member can have various shape, but is preferably circularplate or circular pillar, in view of plural friction material segmentsbeing held on the core surface thereof circumferentially. The onesurface of the holding body can be formed on an end surface of thecircular holding body, or on an outer peripheral edge (corner) thereof.In the former case, a bottom surface(s) of a concaved portion(s) canform the one surface, while in the latter case a surface(s) defining therecess(s) or step(s) can form the one surface. The holding body ispreferably provided with plural segment supplying portions (holdingportions) on the one surface thereof. The segment holding portions canbe comprised plural concaved portion spaced circumferentially, or oneconcaved groove extending circumferentially on the end surface of theholding body. Also, they can be comprised of plural circumferentiallyspaced recesses or steps, or one ring-shaped recess or step. The onesurface can have, at areas into which the friction material segments arecontained, an absorbing portion to absorb the friction material segmentsunder the reduced pressure.

The holding body can be rotatable or non-rotatable depending on acontaining manner (the number of containing positions) of the frictionmaterial segments into the holding body. When the friction materialsegments are contained at one position or few positions, the holdingbody is preferably rotatable to contain then circumferentially. In thiscase, the holding body rotates, after having contained the frictionmaterial segment into respective supplying position, to position it atthe supplying position. Thus, the preceding friction material segment(s)having been contained is positioned at the predetermined positioncircumferentially. To the contrary, when the plural friction materialsegments are contained whole around the holding body, the holding bodyneeds not be rotated.

The first urging member containing the friction material segment(s) onone surface thereof can urge the friction material segment(s) toward theone surface vertical thereto, that is. vertical to a surface of thefriction material segment. It also can urge the friction materialsegment(s) radially inwardly along the one surface, that is, in parallelto the surface of the friction material segment. The urging manner ofthe friction material segment(s) is associated with the location,orientation, number of the one surface and the segment holding portion.

The first urging member can contain one friction material segment, ortwo or more friction material segments with one operation thereofsimultaneously. Configuration of the first urging member can bedetermined depending on the number of the friction material segments tobe contained simultaneously. For example, containing one frictionmaterial segment by one operation one rod-shaped urging member eachcorresponding to each friction material segment can be used. on thehand, for containing all of the friction material segments required(eight to sixty) at once a ring-shaped or circular-shaped urging membercan be used.

In containing the friction material segments at one or few position(s)into the holding body by one or few rod-shaped first urging member(s),the first urging member(s) and the holding body cooperate with eachother so that, after containing of at least one friction materialsegment, the succeeding friction material segment is containedsequentially in the circumferential direction. For such cooperation, theholding body can rotate by the predetermined angle in every containingof the friction material segment (intermittently).

When the first urging member forms a part of the segment preparingmember, a rest of it is formed by the holding body. For example, thesegment preparing member can be constructed by an entry portion of theconcaved portion as the segment holding portion, and a tip end portionof the rod-shaped urging member to be inserted into the above concavedportion. In this case, the first urging member and the holding body needto have punching blade to punch the band-shaped friction material toform the friction material segment. The first urging member and theholding body sufficiently have one punching blade respectively inpunching band-shaped friction material at one portion, but they shouldhave two punching blades respectively in punching it at two portions.Constructing the part of the segment preparing member by the firsturging member reduces the number of parts necessary for preparing andcontaining the friction material segments.

For making the holding body having contained the friction materialsegments and the core plate supported on the supporting member comenear, holding body and/or the core plate need to be moved so that theone surface and the adhering surface come near to each other. For thispurpose, only the holding body or only the core plate can be moved, orboth of the holding body and the core plate can be moved. When theholding body moves relative to the fixed core plate, it can revolveabout a revolving axis, or can move in a direction parallel or verticalto the one surface thereof.

The supporting member supporting the core plate preferably has at leasta mounting surface for the core plate and an attaching/detachingmechanism for the core plate. Preferably, it is rotatable to coat anadhesive agent on an adhering surface of the core plate.

The second urging member for adhering the friction material segmentsheld in the holding body to the core plate by urge is preferably shiftedrelative to the holding body. It can shift in the opposite direction tothe first urging member on the same axis or different (parallel) axes,or it can shift in the vertical direction to the first urging member.The second urging member capable of abutting at a part thereof to thefriction material segment, retracts when the friction material segmentis contained in the holding body but advances when it is adhered to thecore plate. For urging the second urging member, mechanical means suchas a rod-shaped urging member or a hydraulic means such as an aircylinder or an oil cylinder can be used. The mechanical means usuallypushes out the friction material segments, but the hydraulic means canpush out or draw-out them.

In addition, the second urging member can adhere the friction materialsegments one by one, but preferably adhere all of the contained frictionmaterial segments simultaneously to shorten the time period necessaryfor adhering the friction material segments to the core plate.

The embodying modes described in the each of the holding body, the firsturging member, the supporting member, the second supporting member andthe segment preparing member capable of combining selectively should benoted.

BRIEF EXPLANATION OF DRAWINGS

FIG. 1 is a front cross-sectional view of an embodiment 1 correspondingto a manufacturing method of friction plate for clutch of the firstinvention and a manufacturing apparatus of friction plate for clutch ofthe second invention;

FIG. 2 is a bottom view showing, in the embodiment 1, condition forpunching a supplied friction material tape into a friction materialsegment and containing it into a holding body;

FIG. 3 is a front cross-sectional view showing, in the embodiment 1,condition for punching a supplied friction material tape into a frictionmaterial segment and containing it into a holding body;

FIG. 4 is a front cross-sectional view showing condition for coating anadhesive agent on a core plate by a coating member;

FIG. 5 is a front cross-sectional view showing, in the embodiment 1,condition for making the holding body having contained the frictionmaterial segments to come near to the core plate;

FIG. 6 is a front cross-sectional view showing a deformed sample 1 ofthe containing step in the embodiment 1, in which a friction materialtape is punched into a friction material segment by a ring-shapedsegment punch and contained into a holding body;

FIG. 7. is a bottom view showing a deformed sample 2 of the containingstep in the embodiment 1, in which a friction material tape suppliedtangentially is punched into a friction material segment;

FIG. 8 is a front cross-sectional view showing a deformed sample 3 ofthe containing step in the embodiment 1 in which two friction materialtapes supplied at two positions are punched into friction materialsegments and contained in a holding body;

FIG. 9 is a bottom view showing a deformed sample 4 of the containingstep in the embodiment 1 in which plural friction material tapes arearranged radially around a holding body and punched by a ring-shapedsegment punch, and the friction material segments are contained into theholding body;

FIG. 10 is a cross-sectional view along a line A—A in FIG. 9;

FIG. 11 is a front cross-sectional view showing a deformed sample 5 ofthe containing step in the embodiment 1 in which a friction materialtape is punched into a friction material segment by a circular segmentpunch and contained into a holding body;

FIG. 12 is a bottom view showing a deformed sample 6 of the containingstep in the embodiment 1 in which plural friction material tapes arearranged radially around a holding body and punched by a circularsegment punch simultaneously, and the friction material segment arecontained into the holding body;

FIG. 13 is a bottom view showing a deformed sample 7 of the containingstep in the embodiment 1 in which a friction material tape is punchedinto a friction material segment without being trimmed and containedinto a holding body;

FIG. 14 is a front cross-sectional view showing a deformed sample 8 ofthe containing step in the embodiment 1 in which a cutting roller and amating roller are used;

FIG. 15 is a plan view of the deformed sample 8;

FIG. 16 is a front cross-sectional view showing a deformed sample 9 ofthe containing step in the embodiment 1 in which a cutting roller and amating roller are used;

FIG. 17 is a front cross-sectional view of an embodiment 2 correspondingto a manufacturing method of friction plate for clutch and amanufacturing apparatus of friction plate for clutch;

FIG. 18 is a front cross-sectional view of an embodiment 3 correspondingto a manufacturing method of friction plate for clutch and amanufacturing apparatus of friction plate for clutch;

FIG. 19 is a front view showing a roller device used in the embodiment3;

FIG. 20 is a side view of the roller device shown in FIG. 19;

FIG. 21 is a plan view showing condition where a thickness regulatedfriction material tape is punched into a friction material segment;

FIG. 22 is a front view showing another roller device used in theembodiment 3;

FIG. 23 is a side view of the roller device shown in FIG. 22;

FIG. 24 is a plan view showing condition where a thickness regulatedfriction material tape formed by the heat roller of FIGS. 21 and 22 ispunched into a friction material segment;

FIG. 25 is a front view showing still another roller device used in theembodiment 3;

FIG. 26 is a side view of the roller device shown in FIG. 25;

FIG. 27 is a plan view showing condition where a thickness regulatedfriction material tape formed by the heat roller of FIGS. 25 and 26 ispunched into a friction material segment; and

FIG. 28 is a front cross-sectional view of an embodiment 4 correspondingto a manufacturing method of friction plate for clutch and amanufacturing apparatus of friction plate for clutch.

PREFERRED EMBODIMENT OF THE INVENTION

Hereinafter, embodiments and deformed samples of the present inventionwill be explained with reference to attached drawings.

<Embodiment 1>

An embodiment 1 corresponding to a manufacturing method for a frictionplate for clutch of a first invention, and a manufacturing apparatus 1Aof a friction plate for clutch of a second invention for carrying outthe manufacturing method, will be explained based on FIGS. 1 to 5.

This embodiment 1 manufactures, by a manufacturing apparatus 1A of afriction plate for clutch. That is, a friction material tape 2 a istrimmed by a trimming device 3 and punched into a plurality of frictionmaterial segments 2 by the holding body 4 and a segment punch 7 andcontained in the holding body 4 by the segment 7. The friction materialsegments 2 are adhered or pasted to a core plate 9 by a pushing-outmember 7 b.

(Manufacturing Apparatus for Friction Material Plate for Clutch)

The manufacturing apparatus 1A includes a supplying member (not shown)for supplying the friction material tape 2 a to a punching area and thetrimming device 3 for trimming edges thereof, a holding body 4 to punchthe trimmed friction material tape 2 b in a thickness direction thereofcooperating with a segment punch 7 and to hold a plurality of frictionmaterial segments 2 in a containing groove 70 circumferentially, thepushing-out member 7 b for pushing out the friction material segments 2held in the containing groove 70, a rotatable turn table 9 on which acore plate 8 is mounted, and a coating member 10 for coating an adhesiveagent on the core plate 8.

In detail, the trimming device 3, trimming the edges of the frictionmaterial tape 2 a prior to punching thereof, includes movable upper anda lower trimming molds 3 a and 3 b and is located radially outwardly(leftwardly in FIG. 1) and below the holding body 4. The trimming device3 trims the edges 20 of the friction material segments 2 so that thefacing sides 20 a (refer to FIG. 2) of the adjacent friction materialsegments 2 become parallel, when the friction material segments 2 arecontained in the containing groove 70.

A trimming angle of the trimming molds 3 a and 3 b is adjustedcorresponding to a size (width) or the number of the friction materialsegments 2 used for desired the friction material plate for clutch. Theadjustable trimming angle enables the trimming device 3 to trim theedges 20 of the friction material tape 2 a without changing the trimmingmolds 3 a and 3 b, even when size of the friction material segments 2 ischanged.

The holding body 4 includes an upper circular die holder 4 c, acircular-plate-shaped inner periphery punching die 5 (briefly referred“inner die” hereinafter) and a ring-shaped outer periphery punching die6 (briefly referred “outer die” hereinafter) attached to a lower surfaceof the die holder 4 c coaxially. A lower surface of the inner die 5 anda lower surface of the outer die 6 form a lower (end) surface 4 d of theholding body 4. The rod-shaped segment punch 7 can enter into aring-shaped containing recess 70 formed between the inner die 5 and theouter die 6 on the end surface 4 d, and can retract therefrom. A bottomsurface 70 a parallel to the end surface 4 d forms segment supplying(holding) portions. The ring-shaped pushing-out member 7 b disposedwithin the containing groove 70 can go out therefrom axially to push outthe friction material segments 2 toward the core plate 8 mounted on theturn table 9.

The holding body 4 rotatably and shiftably held is controlled a rotationthereof about an axis S1 by every predetermined angle by an indexcontrolling portion 4 a, and is controlled a shift thereof along theaxis S1 (refer to arrows X1 and X2) by a convey controlling portion 4 b.A revolution of the holding body 4 about an axis S3 parallel to the axisS1 is controlled by a controlling portion (not shown) so that theholding body 4 has a punching position facing with the segment punch 7and an upper position above a adhering position facing with the coatingmember 10.

The rod-shaped segment punch 7 disposed below the holding body 4 islifted toward the ring-shaped containing groove 70 and is loweredtherefrom by a driving portion (not shown) as shown by arrows Y1 and Y2.The segment punch 7 is fixed circumferentially of the holding body 4.Entering into the containing groove 70, the segment punch 7 punches thetrimmed friction material tape 2 b at first and second portionslongitudinally spaced by a predetermined distance, with an outerperiphery 7 a, cooperating with the outer periphery 50 of the inner die5 and an inner periphery 60 of the outer die 60. The first portion nearto a tip end of the friction material tape 2 b is punched by the outerperiphery 7 a and the outer periphery 50, while the second portionthereof retracted therefrom is punched by the outer periphery 7 a andthe inner periphery 60. The segment punch 7 pushes the punched frictionmaterial segment 2 into the containing groove 70 to hold it on thebottom surface 70 a. Thus, the segment punch 7 has a functions to punchthe friction material tape 2 b and to push the friction material segment2 into the containing groove 70.

The pushing-out member 7 b held within the containing groove 70 advancesand retracts in directions parallel to the axis S1 by an oil cylinder oran air cylinder (not shown). Being lowered at the adhering positionafter revolution, the pushing-out member 7 b pushes out all of thefriction material segments 2 held in the containing groove 70simultaneously.

The ring-shaped turn table 9 is rotated about the axis S2 parallel tothe axes S1 and S3 by a driving portion (not shown). The turn table 9has a ring-shaped mounting surface 90 on an upper surface thereof, and achucking pawl 91 for chucking the core plate 8 is disposed in a circularhole of the turn table 9.

The coating member 10 disposed above the turn table 9 is reciprocativelymovable radially inwardly and outwardly of the core plate 9 as shown byarrows R2 and R3, and in a direction approaching to and separating fromthe mounting surface 90 of the core plate 9 as shown by arrows Z1 andZ2.

The friction material tape 2 a to be trimmed by the trimming device 3can be produced by forming a wet-type friction material basic paper intoa tape, and then is impregnated a phenol resin as the matrix resin anddried. The basic paper is prepared by mixing a pulp, aramid fiber and afriction adjusting agent by a predetermined ratio. Also, the frictionmaterial tape 2 a can be produced by forming the basic paper into thetape after impregnation of the phenol resin and the drying operation.

Next, the trimming steps for trimming the edges of the friction materialtape 2 a, for punching the friction material tape 2 at the punchingposition and pushing-in the friction material segment 2 in the holdingbody 4, and for pushing-out the friction material segments 2 from theholding body 4 to the core plate 8 at the adhering position will beexplained.

(Trimming Step of Friction Material Tape)

The friction material tape 2 a is supplied radially inwardly of theholding body 4 toward the trimming device 3 as shown by arrow R1 with asupplying member (not shown) by a predetermined pitch. The frictionmaterial tape 2 a thus supplied is trimmed the edges 20 thereof by apair of trimming molds 3 a and 3 b to form a trimmed friction materialtape 2 b. As shown in FIG. 2, the both edges 20 of each segment portionare inclined relative to a longitudinal direction to gradually width andto have isosceles trapezoid-shape.

(Punching of Friction Material Tape and Pushing-in of Friction MaterialSegment)

The trimmed friction material tape 2 b is conveyed radially inwardly ofthe holding member 4 below the inner die 5 and the outer die 6, and isset at position where a tip end portion faces with the containing groove70 formed between the outer periphery 50 and the inner periphery 60.

Next, the segment punch 7 b ascends toward the containing groove 70 asshown by arrow Y2. The friction material tape 2 a is punched at thefirst portion thereof slightly retracted from the tip end by the outerperiphery 50 and the outer periphery 7 a, and is punched at the secondportion retracted from the first portion by a distance by the innerperiphery 60 and the outer periphery 7 a, to form the friction materialsegment 2. The punched friction material segment 2 is pushed into thecontaining groove 70 by the segment punch 7, and is held on the bottomsurface 70 a by engagement of a front end and a rear end thereof withthe inner periphery 60 and the outer periphery 50, respectively.Therefore, even after descending of the segment punch 7, the frictionmaterial segment 2 will not drop from the containing groove 70. Here,some kinds of pressure reducing mechanism (not shown) for absorbing theplural friction material segments 2 in the containing groove 70 can beprovided to hold the friction material segments 2 more securely.

After having punched the preceding friction material segment 2, theinner die 5 and the outer die 6 are indexed by a predetermined anglewith the index controlling portion 4 a. Synchronous therewith, thefriction material tape 2 a is supplied by a predetermined length(slightly larger than length of the friction material segment 2) by thesupplying device and the trimming device 3. Then, the trimming of thefriction material tape 2 b by the trimming device 3, punching of thefriction material tape 2 b by the inner and outer dice 5, 6 and segmentpunch 7 to form the succeeding friction material segment 2 a, andpushing-in of the friction material segment 2 into the containing groove70 by the segment punch 7 are performed in the same way as mentionedabove. Thus, as shown in FIG. 2, the preceding friction material segment2 and the succeeding friction material segment 2 are contained in thecontaining groove 70 side by side circumferentially so that opposingedges 20 a (extending in a radial direction of the holding member 4) areparallel to each other.

With repeating the above steps or processes by plural timescorresponding to the numbers of friction material segments 2 (eight tosixty), the plural friction material segments 2 are formed sequentiallyand are held on the bottom surface 70 a of the containing groove 70circumferentially so that all of opposing edges 20 a of the adjacentplural friction material segments 2 are parallel.

(Pushing-out of Friction Material Segment from Holding Body and Adheringof Friction Material Segment to Core Plate)

In FIGS. 1 and 4, the holding body 4 having held the plural frictionmaterial segments 2 in the containing groove 70 is revolved about theaxis S3 by a controlling portion (not shown) in radius of R by 180degrees to the upper position shown by dotted line above the adheringposition shown by solid line facing the turn table 9. For revolving, theholding body 4 can be mounted on a rotating table for example. As shownin FIG. 4, at the adhering position the axis S1 of the holding body 4coincides with an axis S2 of the turn table 9.

Then, the core plate 8 is coated an adhesive agent by the coating member10. The coating member 10 is moved radially inwardly of the core plate 8as shown by arrow R2 in FIG. 4, and then is lowered to approach to thecore plate 8 as shown by arrow Z3. With rotating the turn table 9 aboutthe axis S2, the coating member 10 coats the adhesive agent on oneannular adhering surface 80.

The number of rotations and rotating angle of the turn table 9 arecontrolled corresponding to the area of the adhering surface 80 to becoated and the coating manner. That is, when the coating agent is coatedon the adhering surface 80 by one round or plural rounds the turn table9 is rotated by one rotation or plural rotations. In both of the oneround coating and the plural round coating, the coating member 10 candischarge the adhesive agent in ring-shaped adhering area (continuouscoating), or can discharge it intermittently to coat the adheringsurface intermittently (intermittent coating).

The coating the core plate 8 by the coating member 10 is preferablyperformed when the holding body 4 is positioned at the upper position toprevent characteristic change of the discharged adhesive agent due todrying. However, the core plate 8 may be coated during pushing-in of thefriction material segments 2 into the containing groove 70 to shortenthe time necessary for coating the adhesive agent.

After completion of the coating to the core plate 8, the coating member10 is separated away from the core plate 8 as shown by arrow Y2 and ismoved radially outwardly as shown by arrow R3.

When the holding body 4 is lowered to the adhering position by theconvey controlling portion 4 b after the adhesive agent coating, thering-shaped pushing-out member 7 b disposed in the containing groove 70is advanced by the oil cylinder as shown by arrow U. Thus, all of theplural friction material segments 2 held on the whole peripheral area ofthe bottom surface 70 a are pushed out toward the core plate 8simultaneously. They are pressed onto and adhered to the adheringsurface 80 of the core plate 8 via the adhesive agent coated in advanceby the coating member 10. In this way, the eight to sixty frictionmaterial segments 2 are adhered to the adhering surface 80circumferentially in one round in a predetermined circumferentialinterval. The opposing sides 20 a of the adjacent friction materialsegments 2 are parallel to form grooves extending radially therebetween.

Thenafter, the pushing-out member 7 b retracts into the containinggroove 70. The holding member 4 is lifted to separate away from the coreplate 8 by the convey controlling portion 4 b, and is revolved by 180degrees the controlling portion to return to the punching position shownin FIG. 1.

Here, when the friction material segments 2 are adhered to the otheradhering surface 81 of the core plate 8, the core plate 8 is reversedthe front/rear surface thereof by loosing the chuck pawl 91, aftercompletion of the coating to one adhering surface 80. The coating to theother adhering surface 81 is performed likewisely. Then the frictionmaterial segment 2 are pushed out by the segment punch 7 from theholding body 4 having once returned to the punching position to containnext set of the friction material segments 2.

The core plate 8 having been coated the adhesive agent on only theadhering surface 80 or on the both adhering surfaces 80 and 81 isremoved from the turn table 9 by loosing the chuck pawl 91, and then issubjected to the second adhering process. In the second process,hardening of the adhesive agent and thickness of the friction materialsegment 2 are adjusted under the predetermined temperature, time periodand pressure respectively set. Thus, the friction material plate forclutch has been manufactured.

The manufacturing method and the manufacturing apparatus of theembodiment 1 render the following advantages.

Firstly, in the punching of the friction material tape 2 b andpushing-in of the friction material segments 2, the outer periphery 50of the inner die 5 and the inner periphery 60 of the outer die 6cooperating with the outer periphery 7 a of the segment punch 7 rotateintermittently by the predetermined angle in every punching. Thus, theouter periphery 50 and the inner periphery 60 punch the frictionmaterial tape 2 b at different punching blade parts. Accordingly, duringone rotation of the inner die 5 and the outer die 6, the particularpunching blade part of the inner periphery 50 and the outer periphery 60punch the friction material tape 2 b only once. As s result, durabilitylife and the allowable times of the punching unit including the innerdie 5, outer die 6 and the segment 7 has extended. In this way, theequipping cost of the manufacturing apparatus, that is, themanufacturing cost for the friction material plate for clutch has beenreduced.

Secondary, the holding body 4 having held the plural friction materialsegments 2 in the containing groove 70 circumferentially at the punchingposition moves to the upper position above to the core plate 8 byrevolution and then descends to the adhering position. The containedplural friction material segments 2 are pushed out simultaneously by thepushing-out member 7 b. As a result, all of the friction materialsegments 2 are adhered to the core plate 8 in the same adheringcondition, that is, the adhering condition of each segment 2 notdifferent. So, they will not shift radially or circumferentially on theadhering surface 80 (81). Thus, the friction material plate for clutchin which all of the plural friction material segments 2 have beenadhered to the same or common circular area of the core plate 8positionally accurate has been obtained.

Further, fiber fabrics formed around the friction material segment 2 inpunching the friction material tape 2 b by the segment punch 7 etc.extend opposite to pressing-in direction of the friction materialsegment 2 into the containing groove 70. However, the friction materialsegment 2 is pushed out from the containing groove 70 opposite to thepush-in direction in adhering to the core plate 8. So, the fiber fabricsnipped by the core plate 8 and the friction material segment 2 can notbe observed, which improve appearance of the friction plate for clutch.

In addition, with pushing in the friction material segment 2 to theholding body 4 only at one position, construction for containing theplural friction material segments 2 into the holding body 4 can be madesimple. Due to revolution of the holding member 4 between the punchingposition and the upper position, shifting construction of the holdingbody 4 can be made simple.

<Deformed Sample 1>

A deformed sample 1 of the punching of friction material tape and thecontaining of friction material segment will be explained. This deformedsample 1 uses, instead of the segment punch 7 in the embodiment 1, aring-shaped and rotatable segment punch 7A shown in FIG. 6. Thisring-shaped segment punch 7A rotatable about the axis S1 has aring-shaped punching blade 7 a at an inner periphery and an outerperiphery thereof which enters the ring-shaped containing groove 70formed between the outer portion 50 of the inner die 5 and the innerperiphery 60 of the outer die 6. The segment punch 7A is lifted andlowered shown by arrows Y1 and Y2 and is rotated intermittently by adrive portion (not shown).

The segment punch 7A, cooperating with the inner die 5 and the outer die6, punches the friction material tape 2 b supplied in a one radialdirection at the first portion slightly retracted from the tip end andthe second portion further retracted therefrom. The friction materialsegment 2 thus formed is pushed into the containing groove 70 by thesegment punch 7A. Then, the segment punch 7A rotates, together with theinner die 5 and the outer die 6, by the predetermined angle for formingthe next friction material segment 2.

In this deformed sample 1, the inner die 5, the outer die 6 and thesegment punch 7A punch the friction material tape 2 b repeatedly atdifferent punching blade parts spaced circumferentially thereof to formeach of plural friction material segments 2. In other words, during onerotation of the inner die 5, the outer die 6 and the segment punch 7A,predetermined part of the punching blade punch the friction materialtape 2 b only once, which has the extended durability life compared withthat of the conventional punching unit.

<Deformed sample 2>

A deformed sample 2 of the punching of friction material tape and thecontaining of friction material segment will be explained.

This deformed sample 2 supplies, a non-trimmed friction material tape 2b of constant width to the holding body 4 including the die holder 4 c,the inner die 5 and the outer die 6 in a tangential direction. Thefriction material tape 2 b is trimmed at two portions spacedlongitudinally thereof by a trimming device (not shown). Then, thefriction material tape 2 b is punched by the inner and outer dice 5 and6 and the segment punch 7 (refer to FIGS. 1 to 5) into the shape similarto the friction material segment 2, and is pushed into the containinggroove 70.

This deformed sample 2 gives flexibility of the supplying direction ofthe friction material tape 2 a.

<Deformed sample 3>

A deformed sample 3 of the punching of friction material tape and thecontaining of friction material segment will be explained.

This deformed sample 3, different from the above embodiment 1 in whichthe friction material tape 2 b is supplied in one position (leftposition of the holding body 4), supplies two friction material tapes 2b in two positions (left position and right position of the holding body4) as shown in FIG. 8. Corresponding to it, two supplying devices (notshown), two trimming devices 3, and two rod-shaped segment punches 7 areprovided. Each of two friction material tapes 2 b is punched by theinner die 5, the outer die 6 and the segment punches 7 into the frictionmaterial segment 2 which is pushed into the containing groove 70 by thesegment punch 7 to be held on the bottom surface 70 a.

According to the deformed sample 3, the time periods necessary forpunching the friction material tape 2 b into the predetermined numbersof the friction material segments 2 and pushing them into the containinggroove 70 have been reduced by half, compared with that of theembodiment 1. Further, the using frequency of the punching unitincluding the inner die 5 the outer die 6 and the segment punches 7 hasbeen reduced by half to extend the durability life thereof.

<Deformed sample 4>

A deformed sample 4 of the punching of friction material tape and thecontaining of friction material segment will be explained.

This deformed sample 4, as shown in FIGS. 9 and 10, fixes all of theinner die 5, the outer die 6 and the ring-shaped segment punch 7 used inthe above deformed sample 1 shown in FIG. 6 circumferentially to set anon-rotatable condition. Further, plural number of the supplying devices(not shown) and trimming devices 3 respectively equal to the number offriction material segments 2 adhered to one core plate 8 are disposedaround the holding body 4 radially and equidistantly in acircumferential direction. Thus, the plural friction material tapes 2 bare supplied radially inwardly simultaneously.

In this deformed sample 4, all of the plural friction material tapes 2 bsupplied radially inwardly in plural directions are punchedsimultaneously by one shot of the inner die 5, the outer die 6 and thering-shaped segment punch 7A at the first portion slightly retractedfrom the tip end thereof and the second portion further retractedtherefrom. Also, all of the punched friction material segments 2 arepushed into the containing groove 70 simultaneously by one shot of thering-shaped segment punch 7A.

According to the deformed sample 4, both of the time period necessaryfor punching the friction material tape 2 b into the plural frictionmaterial segments 2 and for containing the punched plural frictionmaterial segments 2 into the containing groove 70 have been greatlyreduced. In addition, the predetermined punching blade part of the innerdie 5, the outer die 6 and the ring-shaped segment punch 7A has beenused only once during one rotation thereof, which extends the durabilitylife of the inner die 6 and so on.

Here, instead of supplying the plural friction material tapes 2 b wholearound (360 degree) the holding body 4, the friction material tapes 2 bcan be supplied only in a predetermined divided area (180 degrees, 120degrees or 90 degrees) obtained by dividing the surrounding area intotwo, three or four parts. In these cases, the ring-shaped punching unitincluding the inner die 5, the outer die 6 and the segment punch 7A isindexed corresponding to the divided angle area. For example, when thetrimming devices 3 etc. are disposed in the predetermined angle area of180 degrees, the punching unit is rotated by 180 degree between thepreceding punching and the succeeding punching. With such indexing, thepunching unit punches the friction material tapes at different punchingblade parts before and after the indexing, which reduces the usingfrequency of the same punching blade parts. Thus, the punching bladeparts of the inner die 5, the outer die 6 and the segment punch 7A haveextended the durability life.

<Deformed sample 5>

A deformed sample 5 of the punching of friction material tape and thecontaining of friction material segment will be explained.

This deformed sample 5 uses, instead of the inner die 5 and thering-shaped segment punch 7A used in the above deformed sample 1 shownin FIG. 6, a circular plate-shaped segment punch 7B shown in FIG. 11.This segment punch 7B has at an outer periphery thereof a ring-shapedouter punching blade 70 b cooperating with a ring-shaped inner punchingblade 60 a of the outer die 6. A circular-plate-shaped holding portion5A disposed in a hollow portion of the outer die 6 and not having anypunching blade is thinner than the outer die 6 to form a cavity to allowentry of the segment punch 7A. A ring-shaped containing groove 70 informed between the outer periphery of the holding portion 5A and theinner periphery of the outer die 6.

The outer punching blade 70 b punches (shears) the friction materialtape 2 b at one portion retracted from the tip end thereof bycooperating with the inner punching blade 60 a, when the segment punch7A enters the cavity of the outer die 6.

In the deformed sample 5, the friction material tape 2 a advances by adistance corresponding to the length of the friction material segment 2,and is punched by the inner punching edge 60 a and the outer punchingblade 70 b at one portion retracted from the tip end. Thus, the frictionmaterial segment 2 having an arch-shaped inner periphery R11 and anarch-shaped outer periphery R12 are formed. The segment punch 7B and theouter die 6, after having formed the friction material segment 2, arerotated by the predetermined angle (indexed). In this way, the inner die6 and the segment punch 7B punch the friction material tape 2 brepeatedly by the punching blade parts spaced circumferentially, so thatthe using frequency of the same punching blade part reduces. For thisreason, the durability life of the outer die 6 and the segment punch 7Bhas extended compared with that of the conventional punching unit.

Also, in the deformed sample 5, the friction material tape 2 b beingsupplied by the distance substantially corresponding to the length ofthe friction material segment 2, is punched only at one portion.Therefore, when the friction material tape 2 b is punched an arch-shapedtip end R10 of the friction material tape 2 b from which the arch-shapedouter periphery R12 of the punched friction material segment 2 isdivided, forms the arch-shaped inner periphery R11 of the succeedingfriction material segment 2 (refer to FIG. 11). In other words, thearch-shaped tip end R10 of the friction material tape 2 a forms thearch-shaped inner periphery R11 of the friction material segment 2. Forthis reason, almost no part or area of the friction material tape 2 bhas been wastefully used in the punching thereof, which enables toincrease the yielding rate of the friction material tape 2 b and toreduce amount of the punched scrap generated upon punching.

Here, the plural friction material segments 2 held in the containinggroove 70 abut to the outer periphery 50 a of the holding portion 5A andto the inner periphery 60 of the outer die 6, respectively at the innerperiphery and the outer periphery thereof. Thus, the friction materialsegments 2 are prevented from dropping from the containing groove 70.

Also, in this deformed sample 5, two friction material tapes 2 b can besupplied radially inwardly in two directions located in the diameterdirection of the holding body 4, similar to the above deformedembodiment 3 shown in FIG. 8.

<Deformed sample 6>

A deformed sample 6 of the punching of friction material tape and thecontaining of friction material segment will be explained.

In this deformed sample 6, as shown in FIG. 12, the outer die 6 and thesegment punch 7B of the above deformed sample 5 shown in FIG. 11 arefixed circumferentially (non-rotatable), and the plural frictionmaterial tapes 2 b are supplied around the holding body 4.

In detail, as shown in FIG. 12, plural number (equivalent to the numberof friction material segments 2 adhered to one core plate 8 of supplyingdevices (not shown) and trimming devices 3 are disposed whole around theholding body 4 radially and equidistantly in the circumferentialdirection. A circular-plate-shape segment punch 7B having an outerpunching blade 70 b cooperating with an inner punching blade 60 a of thering-shaped outer die 6 is non-rotatable but is lifted and lowered by adriving portion (not shown). When the segment punch 7B enters into thecavity of the outer die 6, the outer punching edge 70 b and the innerpunching blade 60 punch each of all friction material tapes 2 bsimultaneously at one portion retracted from the tip end into the pluralfriction material segments 2. They are pushed into the containing groove70 by the segment punch 7B.

In this deformed sample 6, the outer die 6 and the segment punch 7Bpunch each of the friction material tapes 2 at one portion to form thefriction material segment 2 having the arch-shape inner periphery R11and the arch-shape outer periphery R12. Accordingly, as mentioned in theabove deformed sample 5, almost no tape material has been wastefullyused. Also, the plural friction material segments 2, having been formedsimultaneously by punching the plural friction material tapes 2 b by theouter die 6 and the segment punch 7B, are pushed into the containinggroove 70 by the segment punch 7B simultaneously. As a result, asmentioned in the deformed sample 4 shown in FIGS. 9 and 10, the timeperiods necessary for forming the plural friction material segments 2and for containing them in the containing groove 70 have been greatlyshortened. Further, the inner die 6 and the segment punch 7B, punchingeach of plural friction material tapes 2 b at different punching bladeparts spaced circumferentially, have the extended durability life.

Here, the same deformation mentioned in the above deformed sample 4 canbe made in this deformed sample 6.

<Deformed sample 7>

A deformed sample 7 of the punching of friction material tape and thecontaining of friction material segment will be explained.

The deformed sample 7, as shown in FIG. 13, punches a friction materialtape 2 a into the friction material segment 2 without trimming edges 20thereof, different from the above embodiment 1 and so on.

Here, the two portions of the friction material tape 2 b spacedlongitudinally can be trimmed as occasion demands. When the spaced twoportions are not trimmed as shown in FIG. 13, the friction material tape2 a supplied to the holding body 4 radially inwardly is punched by theinner die 5, the outer die 6 and the segment punch 7 (refer to FIG. 1)into a friction material segment 2 A. The punched friction materialsegment 2A is pushed into the containing groove 70 by the segment punch7. As shown in FIG. 13, the facing sides 20 c are not parallel to eachother.

To the contrary, when the spaced two portions of the friction materialtape 2 a are trimmed by cutting or shearing, the tape 2 a is pushed intothe friction material segment 2A by the inner die 5 and so on. Here,irrespective of trimming of the longitudinally spaced two portions, thefriction material tape 2 a is supplied by the predetermined length andthe holding body 4 is rotated by he predetermined angle synchronoustherewith, in every formation of the friction material segment 2A.

According to the deformed sample 7, no trimming of the edges 20 of thefriction material tape 2 a increases the yielding rate of the tapematerial. In particular, when the longitudinally spaced two portion arenot trimmed, the yielding rate reaches near to 100% theoretically.

It is noted that this deformed sample 7 can be applied to the abovedeformed samples 1 to 6 similarly.

<Deformed Sample 8>

A deformed sample 8 of the trimming of friction material tape and thecontaining of friction material segment will be explained.

This deformed sample 8 uses, instead of the trimming device 3 and thesegment punch 7 in the embodiment 1 and so on, a rotatable cuttingroller 40 having a plurality of cutting blades 40 a on an outerperipheral surface spaced circumferentially, and a mating roller 41opposed to the cutting roller 40 via the friction material tape 2 a.

In detail, the cutting roller 40 rotatable about a fixed shaft andhaving a circumferantial length corresponding to total length of pluralnumber of friction material segments 2 adhered to one surface of thecore plate 8 is formed plural number of cutting blades 40 a thereon.These cutting blades 40 a, when the cutting roller 40 is rotating, notonly trims the edges 20 of the friction material tape 2 b but punchesthe friction material tape 2 b into the friction material segment 2.

The circular plate-shape holding body 45 is comprised of acircular-pillar-shaped member 46 and a ring-shaped member 47 havinglarger height than that of the member 46. As a result, an annularcontaining recess or step 48 is formed by an outer periphery surface ofthe member 46 and an upper surface of the member 47. The upper surface48 a forms a holding surface for holding the friction material segment.A ring-shaped holding surface 48 a is provided with a plurality ofgrooves 48 b extending radially and spaced equidistantly in acircumferential direction as shown in FIG. 15, and is provided with aplurality of absorbing holds 49 connected to an absorbing device (notshown) as shown in FIG. 14. The holding body 45 is positioned relativeto the cutting roller 40 so that the containing step 48 is located belowand lateral of the cutting roller 40. The holding body 45 rotatessynchronous with the cutting roller 40.

Being conveyed by the cutting roller 40 and the mating roller 41radially inwardly of the holding body 45, the friction material tape 2 bis trimmed at the both edges 20 thereof and punched into the fewfriction material segments 2. The punched friction material segments 2are conveyed into the containing step 48 and held on the holding surface48 a by the absorbing force applied through the absorbing holes 49. Withthe synchronous rotation of the cutting roller 40 and the holding body4, the friction material segments 2 continuously formed by punching thefriction material tape 2 b with the cutting roller 40 are sequentiallycontained in each holding portion defined by the groove 48 b.

According to this deformed sample 8, unnecessity of the segment punch 7and so on not only makes construction of the manufacturing apparatussimple, but shorten the time periods required for punching the frictionmaterial tape 2 b and containing the punched friction material segment2. The holding body 4 not punching the friction material tape 2 b doesnot need any punching blade, which makes construction thereof simple.Further, the plural radial grooves 48 b formed on the holding surface 48a prevent shifting of the friction material segments 2 in thecircumferential direction.

Additionally, the cutting roller 40 trimming the friction material tape2 b and punching it into the friction material segments 2 makesprovision of both of the trimming device 3 and the cutting unit 5 to 7unnecessary. Further, using frequency of the cutting blades 40 a forforming the predetermined number of the friction material segments 2decreases compared with that of the trimming device 3. These merits arebrought by the cutting roller 40 forming plural friction materialsegments 2 by one rotation thereof. In this way, the cutting roller 40has the extended durability life.

Here, the two friction material tapes 2 b can be supplied at twopositions spaced circumferentially (for example two positions faced inthe diameter direction (refer to the deformed sample 3 shown in FIG. 8).In this case, two sets of the above cutting rollers 45 and the matingrollers 41 are provided. Such arrangement shortens the time periodnecessary for forming the predetermined number of friction materialsegments 2, and extends the durability life of the cutting roller 40twice that of the prior art.

<Deformed Sample 9>

A deformed sample 9 of the trimming of friction material tape and thecontaining of friction material segment will be explained.

This deformed sample 9 uses, as shown in FIG. 16, instead of thetrimming device 3 etc. having the paired trimming molds 3 a and 3 b inthe embodiment 1, the cutting roller 40 and the mating roller 41 same asthat in the deformed sample 8. Also, instead of the inner die 5, theouter die 6 and the segment punch 71, a circular plate-shaped holdingmember 51, an outer ring-shaped holding member 52, and a pushing-inmember 53 for pushing in the friction material segment 2 into aring-shaped containing groove 70 d formed between the both holdingmembers 51 and 52 are used. All of the holding member 51, the holdingmember 52 and the pushing-in member 53 not having any punching bladeshould be noted. A conveying belt 44 extends between the cutting roller40 and the holding body 45.

The plural friction material segments 2 a continuously formed withpunching the friction material tape 2 a by the cutting roller 40 are,after having been conveyed below the holding body 45 by the conveyingbelt 44, pushed into the containing groove 70 d by the pushing-in member53 to be held on a bottom surface thereof.

According to the deformed sample 9, the cutting roller 40 simultaneouslyforms the plural friction material segments 2 by one rotation thereof,so that the using frequency of the punching blade 40 a is reducedcompared with the using frequency of the above trimming device 3. As aresult, the durability life of the cutting roller 40 has extended. Also,since the friction material tape 2 a is punched by the cutting roller40, the circular-plate-shaped holding member 51, the outer ring-shapedholding member 52 and the pushing-in member 53 not being provided withthe punching function have the simple construction.

<Embodiment 2>

An embodiment 2 corresponding to a manufacturing method for a frictionplate for clutch, and a manufacturing apparatus 1B of a friction platefor clutch for carrying out the manufacturing method will be explainedbased on FIG. 17. This embodiment 2 differs from the above embodiment 1in the former half of the friction material segment adhering step (theprocess to make the holding body 4 come near to the core plate 8) andthe corresponding construction.

In detail, the holding body 4 reciprocatively moves between the punchingposition and the adhering position by linear movements in the horizontaland vertical directions. Corresponding to it, in the manufacturingapparatus 1B, the holding body 4 having contained the friction materialsegments 2 in the containing groove 70 and located at the punchingposition is driven by a driving portion (not shown) in the T1 direction(rightward in FIG. 17)to move to the upper position. Then, it is loweredto the adhering position by the convey controlling portion 4 a to pushout the friction material segments 2 contained in the containing groove70. After having adhered the friction material segments 2 to the coreplate 8, the holding body 4 is lifted up by the convey controllingportion 4 a and then is driven by the controlling portion in the T2direction to move to the punching position. A linear guiding rail (notshown) can be used for guiding the linear movement of the holding body4, for example.

In this embodiment 2, the trimming step, friction material segmentcontaining step and the latter half of the adhering step are same asthat in the above embodiment 1. Corresponding to it, the trimming device3, construction of the holding body 4 other than the driving portion forlinear movement, the turn table 9 and the coating member 10 are same asthat in the above embodiment 1. Here, the trimming step, containing stepand the latter half process of the adhering step and the correspondingconstruction in one of the above the above deformed samples 1 to 9 canbe replaced for that of the embodiment 2.

The manufacturing method and the manufacturing apparatus of theembodiment 2 and the deformed samples 1 to 9 render the followingadvantages, in addition to the advantages of the embodiment 1 and thedeformed samples. That is, the time period necessary for the holdingbody 4 to move between the punching position and the adhering positionis shortened, and no additional space for revolving the holding body 4is required.

<Embodiment 3>

An embodiment 3 corresponding to a manufacturing method for a frictionplate for clutch, and a manufacturing apparatus 1C of a friction platefor clutch for carrying out the manufacturing method, will be explainedbased on FIGS. 18 to 21.

The manufacturing method of the embodiment 3 sequentially performs athickness regulating step of a friction blank material tape 2 a 1, atrimming step of a friction material tape 2 a 2, a containing step of afriction material segment 2B, and an adhering step of the frictionmaterial segment 2B. In other words, the thickness regulating step ofthe friction blank material tape 2 a 1 is performed before the trimmingstep to use a thickness regulated friction material tape 2 a 2,different from the embodiment 1.

Corresponding to it, a manufacturing apparatus 1C of the thirdembodiment has, as shown in FIG. 18, a thickness regulating device 10 isadded to the trimming device 3, the holding body 4 having thepushing-out member 7 b, the segment punch 7 cooperating with the holdingbody 4, the turn table 9 and the coating member 10 of the embodiment 1.The thickness regulating device 10 forms thickness of a friction blankmaterial tape 2 a 1 into a thickness regulated friction material tape 2a 2 by regulating (decreasing) thickness thereof.

(Thickness Regulating Step and Thickness Regulating Device)

The thickness regulating step uses a heat roller device 10 shown inFIGS. 19 and 20. This heat roller 10 is comprised of a circularpillar-shaped lower roller 11 and a circular pillar-shaped upper roller12 opposing therewith. Each of the rollers 11 and 12 has axial lengthlarger than with of the friction material tape 2 a 1 and is providedwith a heat generator (not shown). The both rollers 11 and 12 arearranged so that rotating centers thereof are spaced by distance L whichcan be adjusted. Here, the paired rollers 11 and 12 can be disposed in ahigh temperature environment, instead of being provided with the heatgenerator therein. Also, one of the paired rollers 11 and 12 can beprovided with the heat generator, while the other of them can be set inthe high temperature environment.

The friction blank material tape 2 a 1 supplied to the heat rollerdevice 10 is inserted between an outer peripheral surface 110 of thelower roller 11 and an outer peripheral surface 120 of the upper roller12. Distance t2 (0.3 to 1.0 mm) between the outer peripheral surfaces110 and 120 determined by adjusting distance L between the both centersis smaller than thickness t1 (0.5 to 1.6 mm) of the friction blankmaterial tape 2 a 1. So, the friction blank material tape 2 a 1 isdecreased thickness thereof from t1 to t2 under pressure and heat. Thus,the thickness regulated friction material tape 2 a 2 has been formed.

(Trimming Steps of Friction Material Tape)

The thickness regulated friction material tape 2 a 2 is formed into thetrimmed friction material tape 2 b 1 by being trimmed the edges thereofby the trimming device 3 to have width narrowing configuration. Insteadof the trimming device 3, the cutting roller 40 and the mating roller 41of the above deformed sample 8 shown in FIGS. 14 and 15 can be used.

(Punching and Containing Step of Friction Material Segment)

The trimmed friction material segment 2 b 1 is conveyed in the R1direction toward the holding body 4 until the tip end thereof reaches toposition corresponding to the containing groove 70. Then, as shown inFIG. 21, the friction material tape 2 b 1 is punched into the frictionmaterial segment 2B by cooperation of the inner die 5, the outer die 6and the segment punch 7. The friction material segment 2B is pushed intothe containing groove 70 by the segment punch 7.

The friction material tape 2 a 2, having been heated and compressed inadvance in the thickness regulating step, generates smaller amount offiber-shape or particle-shape cutted chips, when it is punched into thefriction material segment 2B and is pushed into the containing groove70.

Here, instead of the above segment punch 7, the ring-shaped segmentpunch 7A of the deformed sample 1 shown in FIG. 6, or thecircular-plate-shaped segment punch 7B of the deformed sample shown inFIG. 11 can be used. Also, instead of the above holding body 4, theholding body 4 including the circular-plate-shaped holding portion 5Aand the outer die 6 of the deformed sample 5 shown in FIG. 11 can beused.

(Adhering Step of Friction Material Segment)

The friction material segments 2B of the embodiment 3 are attached tothe core plate 8 in the same manner as the friction material segments 2of the embodiment 1 shown in FIGS. 1, 4 and 5. That is, as shown in FIG.18, the holding body 4 having held the plural friction material segments2B in the containing groove 70 moves from the punching position to theadhering position via the revolution about the axis S3 and thesucceeding decrease along the axis S1. Then, all of the frictionmaterial segments 2 in the holding body 4 are pushed out by thepushing-out member 7 b simultaneously and are adhered to the core plate8 mounted on the turn table 9.

Adhering the friction material segment 2B to the core plate 8 in theembodiment 3 renders the advantage of no post treatment for thicknessregulation being required, in addition to the advantages rendered by theembodiment 1. That is, the friction material segment 2 a 2 having beenregulated thickness thereof under heat and pressure in the thicknessregulating process, only requires the hardening treatment of theadhesive agent by the hot press after adhered to the adhering surface 80of the core plate 8.

Here, the holding body 4 can be moved from the punching position to theadhering position via the linear movement in the horizontal directionand the succeeding descending as moved in the embodiment 2.

<Deformed sample 10>

In a deformed sample 10 of the thickness regulating step, it uses a heatroller device 10A shown in FIGS. 22 and 23. This heat roller 10A iscomprised of a circular pillar-shaped lower roller 11, and a convexedupper roller 12 a opposing therewith. Each of the rollers 11 and 12 ahas axial length larger than width of the friction material tape 2 a 1and is provided therein with a heat generator (not shown). The bothrollers 11 and 12 a are arranged so that rotating centers thereof arespaced by distance L which can be adjusted. The convexed roller 12 a ata central portion in an axial direction x thereof, has pluralprotrusions 121 protruded radially outwardly and disposed equidistantlyin a circumferential direction. Each protrusion 121 has height h1 ofabout 0.2 mm from the outer peripheral surface 120, width 1 of about 1to 2 mm, and circumferential length L1 (corresponding to angle θ) ofabout 10 to 20 mm. Interval L2 between the adjacent protrusions 121 isabout 5 to 10 mm.

Here, each dimension of the protrusion 121 can be selectivelydetermined. The paired rollers 11 and 12 a can be disposed in a hightemperature environment, instead of being provided with the heatgenerator therein. Also, one of the paired rollers 11 and 12 a can beprovided with the heat generator, while the other of them can be set inthe high temperature environment.

The friction blank material tape 2 a 1 supplied to the heat rollerdevice 10A is inserted between an outer peripheral surface 110 of theroller 11 and an outer peripheral surface 120 of the roller 12 a asshown in FIGS. 22 and 23. The friction blank material tape 2 a 1 isdecreased thickness thereof from t1 (0.5 to 1.6 mm) to t2 (0.3 to 1.0mm) under pressure and heat. Thus, the thickness regulated frictionmaterial tape 2 a 3 has been formed. Simultaneous with it, a pluralrectangular cavities 22 are formed on the friction material tape 2 a 3equidistantly in the longitudinal direction at an central portion in thewidthwise direction nipped by the peripheral surface 110 of the circularpillar-shaped roller 11 and the protrusions 121 of the convexed roller12 a, due to higher pressure at the central portion than the both sideportions.

The friction material tape 2 a 3 is cutted at a portion positionedbetween the adjacent cavities 22 by the cutting unit including the innerdie 5, the outer die 6 and the segment punch 7 (refer to Fit. 3) to forma friction material segment 2C shown in FIG. 24. The plural cavities 22,when the friction material segments 2C are adhered to the core plate 8,function as oil holding portion for holding lubricant oil therein.

<Deformed sample 11>

In a deformed sample 11 of the thickness regulating step, it uses heatroller device 10B shown in FIGS. 25 and 26. This heat roller 10B iscomprised of a circular pillar-shaped lower roller 11 and a convexedupper roller 12 b opposing therewith. Each of the rollers 11 and 12 bhas axial length larger than width of the friction material tape 2 a 1and is provided therein with a heat generator (not shown). The bothrollers 11 and 12 b are arranged so that rotating centers thereof arespaced by distance L which can be adjusted.

The convexes roller 12 b at a central portion in an axial direction xthereof, has a ring-shaped protrusions 122 protruded radially outwardly.The ring-shaped protrusion 122 has height h1 of about 0.2 mm from theouter peripheral surface 120, and width w1 of about 1 to 2 mm. Here, thepaired rollers 11 and 12 b can be disposed in a high temperatureenvironment, instead of being provided with the heat generator therein.Also, one of the paired rollers 11 and 12 b can be provided with theheat generator, while the other of them can be set in the hightemperature environment.

The friction blank material tape 2 a 1 supplied to the heat rollerdevice 10B is inserted between an outer peripheral surface 11 0 of theroller 11 and an outer peripheral surface 120 of the roller 12 b asshown in FIGS. 25 and 26. The friction blank material tape 2 a 1 isdecreased thickness thereof from t1 (0.5 to 1.6 mm) to t2 (0.3 to 1.0mm) under pressure and heat. Thus, the thickness regulated frictionmaterial tape 2 a 4 has been formed. Simultaneous with it, thelongitudinally extended groove 23 is formed on the friction materialtape 2 a 4 at an central portion in the widthwise direction nipped bythe peripheral surface 110 of the circular pillar-shaped roller 11 andthe protrusions 122 of the convexed roller 12 b, due to higher pressureat the central portion than the both side portions.

The friction material tape 2 a 4 is cutted at plural portions by thecutting unit including the inner die 5, the outer die 6 and the segmentpunch 7 (refer to FIG. 3) to form a friction material segment 2D shownin FIG. 24. The extended groove 23, when the friction material segments2D are adhered to the core plate 8, function as oil holding portion forholding lubricant oil therein.

In addition, as shown in FIG. 27, the friction material segment 2D hastwo segment portions d1 and d2 at both sides of the groove 23. Withselecting width of the friction material tape 2 a 4 corresponding to thecircumferential length of the holding body 4 about twice of the normalfriction material tape 2 b, the single friction material segment 2D canform two segment portions d1 and d2 each corresponding to the normalfriction material segment 2. Such friction material segment 2D shortensthe time periods necessary for punching the friction material tape 2 a 4into the friction material segment 2D and for containing the frictionmaterial segment 2D into the containing groove 70 to half of that in thenormal friction arterial segment 2, respectively.

<Embodiment 4>

An embodiment 4 corresponding to a manufacturing method for a frictionplate for clutch, and a manufacturing apparatus 1D of a friction platefor clutch for carrying out the manufacturing method, will be explainedbased on FIG. 28. This embodiment 4 differs the former half of theadhering step and corresponding construction from that of the aboveembodiment 3.

In detail, the holding body 4 holding the plural friction materialsegments 2B (refer to FIG. 21) formed by punching the thicknessregulated friction material tape 2 a 2 (refer to FIG. 20) is located atthe punching position. It moves from the punching position to the upperposition in the T1 direction by a driving portion (not shown), and thenlowered by the convey controlling portion 4 b. All of the held frictionmaterial segments 2B are pushed out simultaneously by the pushing-outmember 7 b to be adhered to the core plate 8. The holding body 4 havingpushed out the friction material segments 2B is lifted up to the upperposition and moves in the T2 direction to return to the punchingposition. Thus, the embodiment 4 corresponds to deformed sample in whichthe thickness regulating process is added to the above embodiment 2before the trimming step.

Adhering the friction material segment 2D to the core plate 8 in theembodiment 4 renders the advantage of no post treatment for thicknessregulation being required, in addition to the advantages rendered by theembodiment 2. That is, the friction material segment 2 a 2, having beenregulated thickness thereof under heat and pressure in the thicknessregulating process, only requires the hardening treatment of theadhesive agent by the hot press after adhered to the adhering surface 80of the core plate 8.

In the embodiment 4, instead of the friction material segment 2B, thefriction material segment 2C shown in FIG. 24, or the friction materialsegment 20 shown in FIG. 27 can be used.

What is claimed is:
 1. A method of manufacturing a friction plate for aclutch comprising the steps of: cutting a band shaped friction materialinto segments; applying one of the friction material segments onto acircumferential surface portion of a holding body; rotating said holdingbody having the one of the friction material segments applied thereto;applying another of the friction material segments onto anothercircumferential surface portion of the rotated holding body; andadhering the friction material segments held by said holding body to anadhesive adhering surface of a core plate by causing said holding bodyand said core plate to approach one another.
 2. The method of claim 1,wherein each of said applying steps comprises urging one of saidfriction material segments along the respective circumferential surfaceportion in a radial direction of the holding body.
 3. The method ofclaim 1, wherein said holding body has a plurality of absorbing holes,and wherein each of said applying steps comprises urging one of saidfriction material segments onto a respective circumferential surface bya low pressure absorbing force using said absorbing holes.
 4. The methodof claim 1, further comprising at least one urging portion held by saidholding body and shiftable relative thereto, wherein said adhering stepcomprises driving the at least one urging portion to urge a frictionmaterial segment onto an adhesive adhering surface.
 5. The method ofclaim 1, wherein each of said applying steps comprises simultaneouslyapplying two of said friction material segments.
 6. The method of claim4, wherein each of said applying steps comprises simultaneously drivingplural urging portions to urge plural ones of said friction materialsegments.